Q. U.

#4: Preparation of RE/IE Equipment for Mechanical jobs (3 points)

4.1 What lines are to be blinded during a Boiler and TG turnaround?

4.2 What are the safety measures before maintenance permit to works on boiler turnaround?

Q. U. #5: commissioning of RE/E/I Equipment after Mechanical jobs (3 points)

What are the standard operating procedures in commissioning of the following?
5.1 C-1003
5.1 P-1005

Raw/ Sanitary/ Fire Water Distribution

Q. U. #6: Major Equipment and Its Capacity (2 points)

Enumerate all major equipments, tanks and vessels in Raw/Sanitary/fire water distribution facilities in utilities.
Give its service, rating and capacity.

TK-502: raw water storage tank

Capacity: 4770 kL(48ft x 67ft)

TK-223: raw/fire water storage tank

Capacity: (48ft x 80ft)

D-1020: Hydro-pneumatic Drum, sanitary water surge drum to even-out fluctuations in pressure due to varying
demand
Capacity: 1,981mm x 4,877 mm

P-1042A/B/C: fresh water pumps

Capacity: 252.11 m3/H

P-1041A/B/C: sanitary water pumps

Capacity: 45.4 m3/H

Gas Chlorinator: Chlorine feed to D-1020

P-1065A/C: Fire water pumps

P-1065B: Steam-Driven Fire water pump

Capacity: 340.5 m3/H

P-1065D/E/F: Fire water pumps

Capacity: 2000 GPM

Q. U. #7: Flow and Plot Diagram (3 points)

Draw a Sketch of the following indicating path and label equipment:

7.1 Raw Water Distribution
 7.2 Sanitary Water Distribution
7.3 Fire Water Distribution

Q. U. #8: Emergency Condition and Corrective Action (2 points)

A. Describe in detail the emergency indications and corrective actions on the following emergencies
8.1 High level hydro pneumatic Drum
8.2 Raw Water header pressure low: Firewater Header pressure low
B. During a fire Alarm, what are the duties of an offsite technician?

Boiler Water Treatment Plant and Distribution

Q. U. #10: Major Equipment and Its Capacity (2 points)

Enumerate all major equipments, tanks and vessels in Boiler water treatment plant and distribution facilities in
utilities. Give its service, rating and capacity

Deaerating heater, DH-1001/2

Service: Spray tray type BFW Deaerator, mechanically removes Dissolved gases
Capacity: Storage: 20min, Output: 253,680 kg/h

P-1005 A/B/C/D/E/F
Service: BFW pumps to SG-1/2/3/4/5
Capacity: 69 m3/h, Diff. Head: 539,496 mm

P-1005 G/H
Service: BFW pump to GODU/PFCC/CCR/SRU/NHT-2/LPG-2
Capacity: 104 m3/h, Pressure: 5854 kPa

P-1005 I/J/K
Service: BFW pumps to SG-6/7/8
Capacity: 114.5 m3/h, Pressure:5072 kPa

P-1007 A/B
Service: BFW pump to PWF/Hydrogen Unit
Capacity: 44.26 m3/h, Diff. Head– 225,552 mm

P-1068 A/B
Service: BFW pump to MEROX
Capacity: 74.91 m3/h, Diff. Head – 83,820 mm

E-1005
Service: SG-1001/2/3 BFW heater
Capacity: Surface area: 93.84 m2

E-1012A/B
Service: SG-1004/5 BFW heater
Capacity: Surface area: 16m2
E-1013
Service: SG-1006/7 BFW heater
Capacity: Surface area: 83.23 m2

E-1040
Service: SG-1008 BFW heater
Capacity: Surface area: 95m2

E-1080
Service: treated water heater
Capacity: Surface area: 327.114 m2

P-1012
Service: Phosphate injection pump
Capacity: P-1012 A/B/C:0.136 m3/h, P-1012D/E: 1.54 m3/h, P-1012F/G/H/I: 0.002 m3/h

P-1081A/B
Service: Nexguard injection pump

P-1023A/B/C
Service: Eliminox injection pump

P-1024A/B
Service: Triact/Neutralizing Amine injection pump

Q. U. #11: Flow and Plot Diagram (3 points)

Draw a Sketch of the BWTP indicating flow path and label equipment.

Q. U. #12: Emergency Condition and Corrective Action (2 points)

Describe in detail the emergency indications and corrective actions on the following emergencies
12.1 DH-1001/2 Level Low
12.2 BFW Header low pressure

Q. U. #13: Describe in Detail Switching of RO Trains (3 points)

Q. U. #14: Describe in Detail CIP (Cleaning in place) of RO trains (5 points)

Cooling Water Treatment Plant and Distribution

Q. U. #16: Major Equipment and Its Capacity (2 points)

Enumerate all major equipments, tanks and vessels in CWTP. Give its service, rating and capacity.

Major Equipment Summary

1. Cooling Tower No. 1

 Service: Box type, induced draft, spray distribution with two cell and two IDF cooling tower for
Process and Utilities
Capacity: 1,135M3/Hr
2. Cooling Tower No. 2
Service: Box type, induced draft, spray distribution with four cell and Four IDF cooling tower for
Process and Utilities
Capacity: 4,880 M3/Hr
3. Cooling Tower no. 3
Service: Box type, induced draft, spray distribution with one cell and one IDF cooling tower for
Process and Utilities
Capacity: 2,968 M3/Hr
4. Cooling Tower no. 4
Service: Box type, induced draft, spray distribution with one cell and one IDF cooling tower for
Process and Utilities
Capacity: 2,968 M3/Hr
5. P-1040 A/B/C/D
Service: Cooling Water Recirculation pump
Capacity: 499.7 M3/Hr, Head: 620 M, Rpm: 1775
6. P-1050 A/B/C/D
Service: Cooling Water Recirculation pump
Capacity: 1,930.6 M3/Hr, Head: 620 M, Rpm: 1180
7. P-1051 A/B
Service: Cooling Water pump turbine exhaust condensate pump
Capacity: 17 M3/Hr, Head: 56.693 M, Rpm: 3500
8. Chlorinator,CL-1050
Service: Injects CL2 into CT basin to control growth of Slime and Algae in the cooling water
system
Feed Capacity: 0-32Kg/Hr with 1 ton storage cylinder
9. E-1021, Heat Exchanger
Service: Heat exchanger between R.O. Treated water from tank 504 passing at tube side and
exhaust of P-1050A/B passing at shell side.
Capacity: 17 M3/Hr, Head: 56.693 M, Rpm: 3500

10. D-1031,Sulfuric Acid tank

Service: injects H2S04 to CT basin to control PH of the RCW between 8-8.4
Capacity: 1,892.5 L

Q. U. #17: Flow and Plot Diagram (3 points)

Draw a Sketch indicating flow path and label equipment of CW treatments and distribution

Q. U. #18: Emergency Condition and Corrective Action (2 points)

Describe in detail the emergency indications and corrective actions on the following emergencies

18.1 High CW supply temperature with all cells in service.

Indication:
Corrective Action:

18.2 Low CT basin

Indication: LLA-1077 alarms at DCS
 Corrective Action:

18.3 CW contaminated with petroleum base liquid

Indication: Oil is present in the CT basin as well as affected Supply lines
Corrective Action: Increase level of cooling tower to blowdown the oil present in the cooling
water. Investigate source of oil contamination. If excessive oil is present, follow the normal
shutdown procedure

Q. U. #19: Describe in detail E-1021 Shutdown Procedure (3 points)

Q. U. #20: Describe in detail E-1021 Start-up Procedure (5 points)

Compressed Air System and Distribution

Q. U. #22: Major Equipment and Its Capacity (2 points)

Enumerate all major equipments, tanks and vessels in Compressed Air System and distribution facilities in
utilities. Give its service, rating and capacity.

C-1001A/B
Service: Instrument Air for Utilities area
Capacity: 610 SM3/Hr, Discharge Pressure: 689 KPa (g)

D-1011
Service: C-1001A/B Instrument Air receiver
Capacity: 4.3M3

D-1034
Service: C-1001A/B Instrument Air receiver
Capacity: 5M3

Dr-1001
Service: Instrument Air Drier
Capacity: 127 SM3/Hr

Dr-1005
Service: Instrument Air Drier
Capacity: 365 SM3/Hr

Fil-1003
Service: Instrument Air filter
Capacity: 610 SM3/Hr

C-1006A/B
Service: Instrument Air for process area
Capacity: 4579 SM3/Hr, Discharge Pressure: 862 KPa (g)

D-1025
Service: Instrument Air Receiver
Capacity: 6.6 M3
D-1033
Service: Instrument Air Receiver
Capacity: 26 M3

D-1035
Service: Instrument Air Receiver
Capacity: 2222 M3

Dr-1007
Service: Instrument Air Drier
Capacity: 882 SM3/Hr

Dr-1009
Service: Instrument Air Drier
Capacity: 2222 SM3/Hr

Dr-1010
Service: Instrument Air Drier
Capacity:

Fil-1002
Service: Instrument Air filter
Capacity: 2866 SM3/Hr

C-1003
Service: Plant Air Compressor
Capacity: 2544 SM3/Hr, Discharge Pressure: 862 KPa (g)

C-1005A/B
Service: Plant Air Compressor
Capacity: 2290 SM3/Hr, Discharge Pressure: 551 KPa (g)

D-1032
Service: Plant Air Receiver
Capacity: 4.2 M3

Q. U. #23: Flow and Plot Diagram (3 points)

Draw a sketch of the Following indicating flow path and label equipment:
23.1 Draw a schematic diagram of overall process/utilities instrument/plant air system

Q. U. #24: Emergency Condition and Corrective Action (2 points)

Describe in detail the emergency indications and corrective actions on the following emergencies

24.1 C-1006A trips while C-1006B is under repair]

24.1 C-1001A trips while C-1001B is under repair

Steam Generation and Distribution

Q. U. #26: Major Equipment and Its Capacity (2 points)
Enumerate all major equipments, tanks and vessels in Steam Generation and Distribution facilities in utilities.
Give its service, rating and capacity.

Major Equipment Summary

SG-1001/2/3
Service: Steam Generator (Combustion Engineering Fixed with Tangential type burners)
Capacity: Max Continuous Rating (45,300 Kg/Hr); Design Pressure (5171 KPa (g))
Auxiliary: Air Preheater, Forced Draft Fan (steam driven), Induced Draft Fan

SG-1004/5

Service: Steam Generator (Mitsubishi built boiler with frontal fired single burner box)
Capacity: Max Continuous Rating (61,155 Kg/Hr); Design Pressure (5171 KPa (g))
Auxiliary: Forced Draft Fan (steam driven), Economizer

SG-1006/7/8

Service: Steam Generator (Mitsubishi built boiler with frontal fired upper and lower box)
Capacity: Max Continuous Rating (68,200 Kg/Hr); Design Pressure (5171 KPa (g))
Auxiliary: Forced Draft Fan, Economizer

D-1001
Service: SG-1001/2/3 continuous B/D flash drum
Capacity: 11,959 Kg/Hr; Design Pressure: 1,206 KPa (g); Design Temperature: 277°C

D-1050
Service: SG-1004/5 continuous B/D flash drum
Capacity: 11,959 Kg/Hr; Design Pressure: 1,206 KPa (g); Design Temperature: 277°C

D-1040
Service: SG-1006/7/8 continuous B/D flash drum
Capacity: Design Pressure: 1172 KPa (g); Design Temperature: 246°C

E-1008
Service: SG-1001, SG-1002 & SG-1003 Continuous Blowdown/condensate exchanger
Capacity: Surface Area (34.96 m2)

E-1026
Service: Continuous Blowdown/condensate exchanger
Capacity: Surface Area (27 m2)

E-1008
Service: SG-1006/7/8 Continuous Blowdown/Tg-1004/5 cold condensate exchanger
Capacity: Duty (1800MJ/h), Surface Area (17.9 m2)

D-1007
Service: Condensate Storage Drum
Capacity: 3048 mm x 2438 mm

P-1008 A/B
Service: Desuperheater Pumps for MPS
Capacity: 12.5 m3/h; Pressure: 1131 KPa (g)

P-1062A/B
Service: Desuperheater Pumps for Sg-1004/5/6/7/8 SH steam and Process station
Capacity: 8.172 m3/h, pressure: 5318 KPa (g)

Q. U. #27: Flow and Plot Diagram (3 points)

Draw a schematic diagram of Sg-1001 showing its auxiliaries, tube arrangement, burners etc.

Q. U. #28: Emergency Condition and Corrective Action (5 points)

Describe in detail the emergency indications and corrective actions on the following emergencies
28.1 Sg-1001 APH motor drive trip
28.2 Sg-1002 FDF turbine trip
28.3 Sg-1003 IDF motor trip

Q. U. #29: Describe in detail Sg-1001 Shutdown (5 points)

Q. U. #30: Describe in detail Sg-1004 Start-up after T/A (10points)

Fuel Oil/GAS System and Distribution

Q. U. #32: Major Equipment and Its Capacity (2 points)

Enumerate all major equipments, tanks and vessels in Fuel Oil/Gas facilities in utilities. Give its service, rating
and capacity.
Major Equipment Summary

P-1009
Service: Spare F.O. pump
Capacity: 22 m3/h; Pressure: 1103 KPa (g)

P-1010A/B
Service: F.O. pump to Process units
Capacity: 21 m3/h; Pressure: 827 KPa (g)

P-1010C/D
Service: F.O. pump to Sg-1001/2/3/4/5
Capacity: 21 m3/h; Pressure: 1158 KPa (g)
P-1010E/F
Service: F.O. pump to Sg-1006/7/8
Capacity: 20 m3/h; Pressure: 1245 KPa (g)

Vessels
D-1008/9
Service: F.O. Drum for Boilers and Process Units
Capacity: 317,974 Liters

D-1021A
Service: F.G. Knock out Drum
Capacity: Pressure: 517 KPa (g)

D-1021B
Service: F.G. Knock out Drum
Capacity: Pressure: 518KPa (g)

E-1006
Service: Sg-1001/2/3/4/5 F.O. heater
Capacity: Heating Surface Area: 107 m2
E-1007
Service: Process units F.O. heater
Capacity: Heating Surface Area: 107 m2

E-1010
Service: Sg-1006/7/8 F.O. heater
Capacity: Heating Surface Area: 268 m2

Q. U. #33: Flow and Plot Diagram (3 points)

Draw a sketch of the Following indicating flow path and label equipment:
33.1 Fuel oil facilities (include receive and transfer lines from process area to utilities)
33.2 Boilers pilot gas/fuel oil/ fuel gas distribution

Q. U. #34: Emergency Condition and Corrective Action (2 points)

Describe in detail the emergency indications and corrective actions on the following emergencies:
34.1 clog fuel oil pump suction strainer
34.2 PICV-1059 fails open

Caustic Neutralizing Unit and Distribution

Q. U. #36: Major Equipment and Its Capacity (2 points)

Enumerate all major equipments, tanks and vessels in Caustic neutralization unit. Give its service, rating and
capacity.

Tk-702, Tk-703
Service: 25° Baume Caustic Storage tank
Capacity: 158,987 Liters

Tk-704
Service: Odorous Spent Caustic Storage tank
Capacity: 1,033,415 Liters

Tk-2901
Service: Non- Odorous Spent Caustic Storage tank
Capacity: Liters

P-1019
Service: Circulation pump
Capacity: 54 m3/h

P-1020A/B
Service: Fresh Caustic Transfer Pump
Capacity: 11 m3/h

Q. U. #37: Flow and Plot Diagram (3 points)

Draw a Sketch of the following indicating path and label equipment:
37.1 over-all Caustic neutralization unit process

Q. U. #38: CNU emergency procedure (2 points)

38.1 What are the corrective actions to be taken once sulfuric acid line leaks?
38.2 What are the procedures to be done before repairing acid line with leak?

Q. U. #39: Describe in detail CNU Shutdown procedure (3 points)

Q. U. #40: Describe in detail CNU Start up (2 points)

Power Generation and Distribution

Q. U. #36: Major Equipment and Its Capacity (2 points)

Enumerate all major equipments, tanks and vessels in Power Generation facilities. Give its service, rating and
capacity.

TG-1001/2/3/4/5
Service: Turbine driven power generator
Capacity: TG-1001/2: 5000kw, Worthington Turbine: 3600RPM, 1 Curtis 16 rateau, 3000kw straight condensing
Generator: 2 poles, 60 Hz, 3 phase, 4160V, 3600RPM
TG-1003: 5360kw, Elliot Turbine: 5630RPM, 8 rateau, 4300kw straight condensing,
Generator: 4 poles, 60 Hz, 3 phase, 4160V, 1800RPM
TG-1004/5: 7000kw, Elliot Turbine: 6272RPM, 8 stages, 5000kw straight condensing,
Generator: 4 poles, 60 Hz, 3 phase, 4160V, 1800RPM

E-1001/2/3(22,730kg/hr)/4/5
Service: TG-1/2/3/4/5 exhaust surface condenser
D-1003/4/5/44/45
Service: TG-1/2/3/4/5 condensate receiver

Service: Condensate pump

P-1001/2(A/B): 18M3/Hr
P-1003(A/B): 29M3/Hr

Q. U. #43: Flow and Plot Diagram (3 points)

Draw a sketch of the Following indicating flow path and label equipment:
43.1 TG’s automatic gland seal and leak off system
43.2 TG’s Lube oil system.